Thinned building board

ABSTRACT

A thinned building board comprises multiple block units and at least one strengthening unit. The multiple block units are laminated with one another, and each block unit comprises a light material. Each one of the at least one strengthening unit is located between two adjacent block units. Each of the block units, which are made of porous material, can tightly connect to the adjacent block units as an integrated whole via the strengthening units, so the thinned building board has enhanced strengthening structure and is not prone to fragmentation. Meanwhile, the thinned building board has soundproof, sound-absorbing, fireproof and heatproof effects by the properties of the porous material, and the block unit of the thinned building board is bound by the light material, and then manufactured through specific stacking, combining, shaving, and cutting, so that the thinned building board has low manufacture cost.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a board, especially to a thinned building board for use on constructions and buildings.

2. Description of the Prior Arts

In general, for the purposes of comfort and safety of people in the building, the walls and the ceilings are installed with building materials that have soundproof, fireproof or heatproof effects, such as glass wool or polystyrene, etc.

The glass wool has great heatproof, fireproof, sound-absorbing and soundproof properties, but it also tends to produce glass fibers scattering in the air. Glass fibers cause allergy when contacting human skin, or may further damage health when entering from the respiratory track into human body. After use for a period of time, the interior of the glass wool will be wet because of absorbing water vapor in the air, such that the sound-absorbing and soundproof effects deteriorate.

The polystyrene has great heatproof, soundproof and waterproof properties. However, when polystyrene is exposed to heat (up to the melting point), it will melt and can hardly be fireproof, and will release toxic gases and flammable gases, incite production of flames and spread of fire, and cause pollution.

In order to solve the disadvantages in soundproof, sound-absorbing, heatproof and fireproof effects of glass wool and polystyrene, conventionally, glass wool and polystyrene are replaced with foam cement boards, foam glass boards, ceramic grain boards or marble boards. However, foam cement boards, foam glass boards and ceramic grain boards are made of materials such as lime, glass, ceramic grain etc. together with foaming agent, adhesive, etc., and gaps are formed between the materials and adhesive, and between the adjacent two materials, causing poor structural strength. The boards when made thinned are thus fragile. As a result, conventional foam cement boards, foam glass boards and ceramic grain boards are thick in unit but cannot be made into large area.

Although conventional marble boards can be cut into a thin board from the original marble rock, excavating marble from the mining site is complicated, and cutting and shaving the marble into the thin board is time-consuming with relative high cost.

SUMMARY OF THE INVENTION

According to the above disadvantages, the present invention provides a thinned building board which has better structural strength, is not prone to fragmentation, and has soundproof effects, sound-absorbing effects, fireproof effects, heatproof effects, and low cost.

In order to achieve the above purpose, the present invention provides a thinned building board, comprising multiple block units which are laminated with one another, and each block unit is composed of a light material; and at least one strengthening unit is each mounted between two adjacent ones of the multiple block units.

According to the present invention, the light material includes, but is not limited to, cement, vermiculite, foam rock, foam glass and recycled grains of ceramic foam.

The advantages of the present invention are as follows: each of the block units, which are made of light material, can tightly connect to the adjacent block units as an integrated whole by the strengthening units, so the present invention has better structural strength, is not prone to fragmentation, and has thinner thickness and larger board area. Meanwhile, the present invention has soundproof, sound-absorbing, fireproof and heatproof effects by the properties of the light material, and the block unit of the present invention is bound by the light material, and then manufactured through specific stacking, combining, shaving and cutting. The present invention is made of light material which is less costly and easier to obtain, so that the present invention has lower manufacture cost.

Preferably, each of the block units are laminated with one another and stacked in matrix arrangement, thereby having enhanced structural strength to resist the shear stress from cutting and the vibrating force from shaving.

Preferably, a strengthening grid is embedded in each of the at least one strengthening unit for enhancing the entire structural strength of the building board.

More preferably, each block unit comprises multiple sub-block units; the sub-block units of the same block unit are laminated with one another and arranged in parallel, and a reinforcing layer is located between each two adjacent sub-block units of the same block unit. A strengthening grid is embedded in each of the at least one strengthening unit. Preferably, the sub-block units of the adjacent block units are arranged perpendicularly with each other. For example, the arrangement of the sub-block units of the block unit is vertical, and then the arrangement of the sub-block units of the adjacent block unit is horizontal, whereby the structural strength can be enhanced and the building board will not be prone to fragmentation by the vibration of shaving process.

Other objectives, advantages and novel features of the invention will become more apparent from the following detailed description when taken in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of the first preferred embodiment of the thinned building board of the present invention;

FIG. 2 is a flowchart of the manufacturing of the thinned building board in FIGS. 1; S1, S2 and S3 represent Step 1, Step 2 and Step 3 respectively;

FIG. 3 illustrates Step 1 of manufacturing the first embodiment of the thinned building board in FIG. 1;

FIG. 4 illustrates a front view of Step 2 of manufacturing the first embodiment of the thinned building board in FIG. 1;

FIG. 5 illustrates a right side view of Step 2 of manufacturing the first embodiment of the thinned building board in FIG. 1;

FIG. 6 illustrates Step 3 of manufacturing the first embodiment the thinned building board in FIG. 1;

FIG. 7 is a perspective view of a second preferred embodiment of the thinned building board of the present invention;

FIG. 8 illustrates manufacturing of the second preferred embodiment of the thinned building board of the present invention;

FIG. 9 is a perspective view of a third preferred embodiment of the thinned building board of the present invention;

FIG. 10 illustrates a first operational view of the first preferred embodiment of the thinned building board of the present invention;

FIG. 11 illustrates a second operational view of the first preferred embodiment of the thinned building board of the present invention; and

FIG. 12 illustrates an operational view of the third preferred embodiment of the thinned building board of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

As shown in FIG. 1, the first preferred embodiment of the present invention provides a thinned building board comprising multiple block units 10 and at least one strengthening unit 20.

As shown in FIG. 1, the multiple block units 10 are laminated with one another, and each block unit comprises a light material, wherein the light material includes, but is not limited to, cement, vermiculite, foam rock, foam glass and recycled grains of ceramic foam which have soundproof, sound-absorbing, fireproof or heatproof effects. Furthermore, each of the block units 10 comprises foaming agent or adhesive.

As shown in FIG. 1, each one of the at least one strengthening unit 20 is mounted between two adjacent block units 10, and each strengthening unit 20 comprises a strengthening grid 21. In a preferred embodiment, each strengthening unit 20 is a cement adhesive layer, and the strengthening grid 21 of each strengthening unit 20 is a fiberglass grid.

As shown in FIGS. 1 to 3, the manufacture of the first preferred embodiment of the thinned building board is as the following: each block unit 10 is made of a block 30, and the block 30 is manufactured from a light material bound under room temperature. Multiple blocks 30 are laminated and stacked on one another. Each strengthening unit 20 is made of a strengthening body 40. A bulk unit 50 is made from the strengthening bodies 40 bound between the adjacent blocks 30 (S1). As shown in FIGS. 2, 4 and 5, the bulk unit 50 is cut to form multiple slabs 51 (S2), and a bulk 60 is made from the strengthening bodies 40 bound between the adjacent slabs 51, as shown in FIGS. 2 and 6. The bulk 60 is cut into slices to obtain the thinned building board of the first preferred embodiment of the present invention (S3) as shown in FIGS. 1 and 2.

As shown in FIGS. 7 and 8, in the second preferred embodiment of the present invention, a block unit 10A is made from a block body 70A, and the block body 70A is manufactured from a porous material. Multiple block bodies 70A are arranged in parallel, and then a reinforcing layer 12A is bound between the adjacent block bodies 70A to form multiple blocks 30A. A bulk 60A is composed of the blocks 30A and strengthening bodies 40. On the cross section of the bulk 60A, sub-block units 11A of the adjacent block units 10A are arranged perpendicularly to each other, each of the block bodies 70A of the same block 30A are laminated and arranged in parallel, and the block bodies 70A of the adjacent blocks 30A are arranged perpendicularly to each other. As a result, the bulk 60A has better structural strength to resist shear stress of the cutting, so that the bulk 60A will not easily break during the cutting process. The bulk 60A is cut into slices to obtain the thinned building board of the second preferred embodiment of the present invention.

As shown in FIG. 7, in a second preferred embodiment of the present invention, each block unit 10A comprises multiple sub-block units 11A, and the sub-block units 11A of the same block unit 10A are laminated in parallel with one another. Furthermore, the sub-block units 11A of each block unit 10A are arranged perpendicularly to the sub-block units 11A of an adjacent block unit 10A. For example, the sub-block units 11A of the block unit 10A are arranged vertically, and the sub-block units 11A of the adjacent block unit 10A are arranged horizontally. A reinforcing layer 12A is located between two adjacent sub-block units 11A, and the reinforcing layer 12A comprises a sub-block unit 121A which is coated by the reinforcing layer 12A. Preferably, each reinforcing layer 12A is a cement adhesive layer, and the sub-block unit 121A of each reinforcing layer 12A is a fiberglass grid.

As shown in FIG. 9, in a third preferred embodiment, multiple block units 10B are sequentially laminated with one another. Each block unit 10B comprises multiple sub-block units 11B, the sub-block units 11B of the same block unit 10B are laminated in parallel, and the sub-block units 11B of each block unit 10B are arranged perpendicularly to the sub-block units 11A of the adjacent block unit 10A. A reinforcing layer 12B is located between each two adjacent sub-block units 11B, and a strengthening unit 20B is located between each two adjacent block units 10B.

Further, in the first preferred embodiment as shown in FIG. 1, each block unit 10 is formed as, but not limited to, a square; in the second and third preferred embodiments as shown in FIGS. 7 and 9, each sub-block unit 11A, 11B of the block unit 10A, 10B is formed as, but not limited to, a rectangle. More preferably, the shapes of each block unit 10, 10A, 10B and each sub-block unit 11A, 11B depend on the structural strength and the desired shape of the finished product, i.e., the thinned building board, which is determined in advance.

The advantage of the thinned building board of the present invention is that each block unit 10, 10A, 10B, which is made of porous material, can tightly connect to the adjacent block unit 10, 10A, 10B by each strengthening unit 20. Furthermore, each sub-block unit 11A, 11B, which is made of porous material, can tightly connect to the adjacent sub-block unit 11A, 11B by the strengthening unit 12A, 12B. As a result, the present invention provides enhanced structural strength, fragmentation resistance, thinner thickness and larger board area. Thus, the thinned building board of the present invention can solve the shortcomings of the conventional foam cement boards, foam glass boards and ceramic grain boards that are unable to be made into thinner boards due to weak structure.

On the other hand, the thinned building board of the present inventions can be directly installed on the wall for soundproof, fireproof or heatproof purposes, it also can be stacked on one another and combined into street furniture, exterior wall panels or public arts. Due to the enhanced structural strength of the thinned building board of the present invention, the building material formed from the present invention also can provide enhanced structural strength.

In another aspect, the thinned building board of the present invention is bound by light material, and then manufactured through specific stacking, combining, shaving and cutting. Compared to the marble board which requires shaving and cutting the marble rock from mining, the thinned building board of the present invention uses the light material which is less costly and easier to obtain and has the same properties with the marble board, such that the present invention has lower manufacturing cost.

Furthermore, the conventional method for clay firing is widely used in irregular building material because it is easy to manufacture irregular shapes. To avoid the irregular, especially large-scale, building material from deformation or collapse then losing its original shape during sintering, heat-resistant jigs or struts as support are manufactured in advance. However, the cost is remarkable. When the thickness of the building material is increased to avoid collapse during the sintering process, the building material will induce internal stress. When the building material breaks by the internal stress released after alternating of high and low temperatures, the lifetime of the building material decreases.

As the thinned building board of the present invention provides enhanced structural strength and will not easy break or deform during cutting process, the present invention can be solidified at room temperature and also has heat-resistant property. The thinned building board of the present invention can be manufactured at first, and then made into an irregular building by cutting, craving, stacking or sintering process, and the supporting jigs are not needed during sintering process so that the cost for jigs will be saved.

As shown in FIGS. 1, 10 and 11, in one of the preferred embodiments, the thinned building boards of the present invention are respectively processed for shape cutting by computer numerical control (CNC) cutting machine. A base 80 is formed by stacking, laminating and combining multiple thinned building boards of the present invention after the cutting process, and then the surface of the base 80 is coated with a slurry interface layer for combination as an integrated whole of the base 80 with glass glaze or glass paint during high temperature of sintering process. A surface layer 81 is formed by the slurry interface layer with glass glaze or glass paint to form a specific shape or pattern of the building material. Meanwhile, the purpose of high temperature sintering is only to combine the surface of the base 80 and the slurry interface layer with glass glaze or glass paint, such that the time of sintering process can be shortened, the resource cost can be saved without the need to wait for temperature drop, and the time will be saved.

In another preferred embodiment, the thinned building board of the present invention which has suitable structural strength is chosen for a pre-determined irregular shape. The thinned building board of the present invention is chosen for stacking for obtaining the optimal structural strength, and then carved to obtain irregular building material or object having the preferred structural strength. As shown in FIGS. 9 and 12, a chair 90 is composed by the combination of the thinned building board of the third preferred embodiment of the present invention and other suitable building boards. Therefore, except for directly used as a building board, the present invention also can be made into building material, street furniture, exterior wall panels or public arts having preferred structural strength and irregular or specified shape, which is achieved by cutting, stacking, etc.

Even though numerous characteristics and advantages of the present invention have been set forth in the foregoing description, together with details of the structure and features of the invention, the disclosure is illustrative only. Changes may be made in the details, especially in matters of shape, size, and arrangement of parts within the principles of the invention to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed. 

What is claimed is:
 1. A thinned building board, comprising: multiple block units which are laminated with one another, each block unit comprising a light material; and at least one strengthening unit each mounted between two adjacent ones of the multiple block units.
 2. The thinned building board according to claim 1, wherein the block units are stacked in matrix arrangement.
 3. The thinned building board according to claim 1, wherein each block unit comprises multiple sub-block units; the sub-block units of the same block unit are laminated with one another and arranged in parallel, and a reinforcing layer is located between each two adjacent sub-block units of the same block unit.
 4. The thinned building board according to claim 3, wherein the sub-block units of the adjacent block units are arranged perpendicularly to each other.
 5. The thinned building board according to claim 1, wherein a strengthening grid is embedded in each of the at least one strengthening unit.
 6. The thinned building board according to claim 2, wherein a strengthening grid is embedded in each of the at least one strengthening unit.
 7. The thinned building board according to claim 4, wherein a strengthening grid is embedded in each of the at least one strengthening unit.
 8. The thinned building board according to claim 3, wherein a reinforcing grid is embedded in each of the reinforcing layers.
 9. The thinned building board according to claim 7, wherein a reinforcing grid is embedded in each of the reinforcing layers.
 10. The thinned building board according to claim 5, wherein the strengthening grid of each strengthening unit is a fiberglass grid.
 11. The thinned building board according to claim 6, wherein the strengthening grid of each strengthening unit is a fiberglass grid.
 12. The thinned building board according to claim 9, wherein the strengthening grid of each strengthening unit is a fiberglass grid.
 13. The thinned building board according to claim 8, wherein the reinforcing grid of each reinforcing layer of each block unit is a fiberglass grid.
 14. The thinned building board according to claim 12, wherein the reinforcing grid of each reinforcing layer of each block unit is a fiberglass grid.
 15. The thinned building board according to claim 3, wherein the reinforcing layer of each block unit is a cement adhesive layer.
 16. The thinned building board according to claim 14, wherein the reinforcing layer of each block unit is a cement adhesive layer.
 17. The thinned building board according to claim 1, wherein the light material includes foam cement, vermiculite, foam rock, foam glass or recycled grains of ceramic foam.
 18. The thinned building board according to claim 2, wherein the light material includes foam cement, vermiculite, foam rock, foam glass or recycled grains of ceramic foam.
 19. The thinned building board according to claim 16, wherein the light material includes foam cement, vermiculite, foam rock, foam glass or recycled grains of ceramic foam. 